PERSPECTIVE REFRACTORY AND HEAT-INSULATED

MATERIALS AND COATINGS FOR EXTREMAL OPERATION
CONDITIONS

Vladimirov V.S. , Karpuhin I.A. (1), Iluhin M.A.(2), Moyzis S.Y. (3), Moyzis Y.S. (4)

MSTU n/a N.E. Bauman, Moscow, Vtoraya Baumanskaya str., 5; E-mail:

(1- 4) ZAO NPKF «MaVR», Zhukovsky, М.R., Gagarina str., 2, E-mail:

Development of new refractory and heat-insulated materials and coatings, operated under extreme conditions (high temperatures and 2-phase flow blower speeds, aggressive conditions, complex and alternating loadings and etc.) is one of the most important modern problem, being actual not only for aero-space engineering, but also for any civil branches of national economy.
During last six years ZAO NPKF «MaVR» with participation of collaborators of MSTU n/a N.E. Bauman, TsAGI, FRI
develops and introduce new types of refractory and heat-insulated materials and coatings, having more higher operational features and characteristics in comparison with traditional features and characteristics into different branches of national economy. For receiving of the same materials base special technological processes, using perspective technology of self-extending high-temperature synthesis (SHS), cold swelling and its joint application are developed.
SHS-technology is based on the principles of combustion without gas of systems oxidizer-fuel, going in condensed phase. Opportunity of the same combustion without gas is conditioned by above all high values of heat-evolution under chemical interaction and thermal stability of combustion products. In particular these factors determines formation of the same chemical structures of final products, capable to stand the high thermal, mechanical and chemical loadings without changing of main characteristics in wide range of influences. High speeds of SHS-processes determine its high productivity, impenetrable for traditional methods on development of materials with increased operational characteristics.
/ Method of cold swelling for non-organic compositions are executed under room temperature without any heating and forming of special conditions. Swelling effect is as usual based on reactions of chemical interactions of two or more components of compound with formation of gasiform products of reaction. Effectiveness of this method depends on the right selection of components.
On the basis of mentioned and other modern technologies ZAO NPKF «MaVR» developed the series of new non-molded refractory and heat-insulated materials and coatings and at the present time deliver them to any Customers.
At the present time production is organized for the following types of non-molded materials:
- dry technological compounds for receiving of thin (0,5…2,5 mm) ceramic SHS-coatings with the specified operational features (more than 15 kinds of compositions);
- SHS-mortars for «welding» by ceramic joint into monolith for different kinds of refractory products (more than 5 kinds);
- dry technological compounds for formation on the working surfaces of piece-goods and refractory concretes of thick-wall (4…10 mm) ceramic plasters (more than 10 kinds);
- dry technological compounds for receiving of gunite-masses and repair-restoration solutions (more than 5 kinds);
- dry technological compounds for receiving of refractory light (r=500….1200 kg/m3) and particularly light (200 ….500 kg/m3) cellular concretes (more than 15 kinds) by the cold swelling method;
- dry compounds and liquid components for receiving metal-phosphate refractory coatings and plasters (more than 5 kinds);
- dry technological compounds for production of glue compositions and mastics for gluing of heat-insulated porous strong-formed and fibrous materials;
- dry technological compounds for production of coatings, plasters, concretes and anti-burnt-on paints for aluminium productions.
Application of these mentioned non-formed materials allows:
- to form on the working surfaces of some wide-used refractory materials: piece refractors (of alumino-silicate, alumina, silica, periclaz-spinellide and other classes), refractory concretes and also mullite-siliceous and corundum fibrous materials – protective-strengthening coatings and plasters with the specified operational features;
- to combine into monolith using specially selected compositions of mortars (SHS-masonry solutions) piece refractors of alumino-silicate, alumina, silica, periclaz-spinellide and other classes, at that the oxide-ceramic material formed in the region of joint is substantially more strong, more erosion- and corrosion-stable in comparison with the rest laying;
- to execute of extreme and plan repair and repair-restoration works for linings of high-temperature thermal aggregates (metallurgical aggregates, heating furnaces, boilers, chemical reactors, columns, scrubbers and others) due to application of gunite-masses, repair-restoration solutions, glue compositions, concretes, coatings and plasters, mentioned above;
- to form all the necessary heat-protective elements for structures of high-temperature thermal aggregates at the place of execution of lining and repair works with the usage of casting technology (on the base of application of technological admixtures for receiving of light and particularly light refractory cellular concretes).
Dry technological compounds are also widely used at the experimental production shop of «MaVR» during the production of numerous nomenclature of ready products: blocks, bricks, plates, bars, shells and etc.
Developed non-formed refractory materials are successfully approved and demonstrated their high effectiveness in the real conditions of / operation at more than 60 enterprises, plants and industrial complexes of different branches of industries; and at the present time some of them (SHS-mortars, dry compounds for receiving of coatings, plasters and repair-restoration compositions) are widely used during operation of high-temperature thermal aggregates and during execution of lining works at the enterprises of ferrous and non-ferrous metallurgy, machine-building, chemical and petrochemical industry, heat-and-power engineering, municipal economy and etc.
At the enterprises mentioned above non-formed refractory and heat-insulated materials of «MaVR» firm were effectively used during execution of repair and repair-restoration works for linings of the following types of high-temperature thermal aggregates and elements of their structures:
- metallurgical furnaces (open-hearth, electric arc steel-smelting, inductive for smelting of cast iron and non-ferrous metals, catoptrical for smelting of non-ferrous metals, cupolas and furnaces-scoops for smelting of steel);
- scoops (steel-pouring, intermediate scoops for pouring of steel, scoops for pouring of cast iron, small filling scoops for conveyer filling of cast iron into forms, vacuum and filling scoops for smelted aluminium and its alloys and so on);
-  steam and water-heated boilers,
recuperators, burner blocks, protective cocks, gas flues and smoke-stacks;
-  chemical reactors, high-temperature
columns, pyrolysis furnaces, baths and scrubbers;
- heating furnaces of press-forging, instrumental and rolling productions;
- burning and heating furnaces for productions of construction industry;
- cremation installations and furnaces for burning of different kinds of waste products.
At the present time works on expansion of nomenclature for output products, and also on development of new types of refractory composite concretes, plasters, coatings and gunite-masses are successfully carried out.